Senior Engineer, Process Development & Sustaining Engineering
Confirmed on the employer's own hiring board on Nov 2, 2026. First seen by Alion on Oct 30, 2026. Western Digital scores B on the Alion truth index.
WD is building the infrastructure behind the AI-driven data economy.
As AI scales, so does data. Every interaction, every model, every system generates data that must be stored, managed, and made accessible over time. That’s where we come in.
We combine deep engineering expertise with global-scale manufacturing to deliver the storage systems that make AI possible, powering hyperscale data centers, cloud platforms, and enterprise infrastructure worldwide.
This isn’t theoretical work. It’s real systems, at real scale, people solving some of the hardest challenges in technology today.
We’re looking for people who want to build, solve, and operate at that level.
Join us and let’s shape the future of data.
Job Description
The Senior Engineer, Process Development & Sustaining will lead the development, optimization, and sustaining of manufacturing processes for WD's HDD storage products. This is a technically deep, cross-functional role requiring strong foundation in chemistry, materials science, or chemical engineering.
You will drive process characterization, chemical/material qualification, and yield improvement initiatives while ensuring manufacturing processes remain stable, compliant, and cost-competitive. You are expected to operate with high technical autonomy, interface with global R&D and process teams, and mentor junior engineers on the Penang floor.
This role is ideal for a Master's, or Bachelor's graduate in Chemical Engineering or Materials Science who is passionate about translating lab-scale science into high-volume manufacturing solutions.
Key Responsibilities
Process Developmen t
- Design and develop new manufacturing processes or significantly improve existing ones for HDD production
- Conduct Design of Experiments (DOE) to characterize process windows, identify critical process parameters (CPPs), and optimize process outputs
- Evaluate and qualify new chemicals, materials, and process consumables for manufacturing use
- Develop process recipes, control plans, and standard operating procedures (SOPs)
- Translate R&D/lab-scale processes into robust, scalable, high-volume manufacturing processes
Process Sustaining
- Own sustaining engineering for assigned process modules - ensure processes remain stable, in control, and within specification
- Monitor Statistical Process Control (SPC) charts; respond to out-of-control signals with structured problem-solving
- Lead Engineering Change Orders (ECOs) for process changes, chemical substitutions, and material updates
- Manage process deviation requests and ensure timely resolution
- Maintain process documentation, control plans, and work instructions per WD QMS
Chemical & Material Engineering
- Lead chemical/material qualification activities including incoming material testing, process compatibility studies, and shelf-life evaluations
- Evaluate alternative chemistries and materials for cost reduction, sustainability, or supply chain risk mitigation
- Work with EHS team to ensure safe handling, storage, and disposal of process chemicals per regulatory requirements
- Support RoHS, REACH, and PFAS compliance reviews for process chemicals and materials
Yield & Quality Improvement
- Lead yield loss analysis and drive structured RCCA (Root Cause and Corrective Action) for process-related defects
- Apply Six Sigma / SPC / Lean methodologies to reduce process variation and improve Cpk
- Partner with Quality Engineering to resolve customer escapes and field returns linked to process issues
- Drive continuous improvement projects with measurable cost and quality impact
NPI & Technology Transfer
- Support New Product Introduction (NPI) process readiness - from process concept to mass production release
- Lead or support technology transfer of new processes from R&D/HQ to Penang manufacturing
- Develop process qualification protocols (PQ), installation qualification (IQ), and operational qualification (OQ) plans
Cross-Functional Collaboration
- Interface with R&D, Product Engineering, Quality, EHS, Supply Chain, and Equipment Engineering teams globally
- Present process data, findings, and recommendations to senior management and global stakeholders
- Collaborate with equipment engineers on process-equipment interactions and optimization
People & Mentorship
- Mentor and coach junior and mid-level process engineers
- Lead technical reviews, knowledge-sharing sessions, and engineering forums
- Support capability building within the Penang process engineering team
Academic Qualification :
- Bachelor's Degree (BSc/BEng) in Chemical Engineering, Materials Science, or related discipline with strong industry experience
- Master's Degree (MSc/MEng) in Chemical Engineering, Materials Science, Chemistry, Polymer Science, or related field
Experience and Skills Required :
- Minimum 5-10 years experience in process or manufacturing environment.
- Knowledge on HDD media cleaning technology will be added advantage.
- Knowledge in SPC, FMEA, Technical Report Writing and DOE run.
- Green Belt or Lean Six Sigma will be and added advantages.
- Good technical presentation skill.
- Good communication skill.
Technical Skills - Core
- Strong fundamentals in chemistry, materials science
- Proficiency in DOE methodologies (full factorial, RSM, Taguchi)
- Working knowledge of Statistical Process Control (SPC) and statistical analysis tools (JMP, Minitab, or equivalent)
- Familiarity with thin film, surface treatment, wet chemical, cleaning
- Understanding of failure analysis techniques (SEM, EDX, XRD, FTIR, or equivalent)
- Knowledge of chemical safety, EHS regulations, and REACH/RoHS compliance
WD thrives on the power and potential of diversity. As a global company, we believe the most effective way to embrace the diversity of our customers and communities is to mirror it from within. We believe the fusion of various perspectives results in the best outcomes for our employees, our company, our customers, and the world around us. We are committed to an inclusive environment where every individual can thrive through a sense of belonging, respect and contribution.
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